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DIESELFACTS
SERVICE ENGINES TURBOCHARGERS PROPULSION SYSTEMS MARINE STATIONARY
2006 1
Overhaul success
Factory freezer given
new life
Page 2
Clean two-stroke power
Power station uniting
green technologies
Page 4
Diesel Academy Expansion
ME training places
expanded globally
Page 5
Crankshaft specialists
Shrink-fitting operation
saves 10 months
Page 6
New engines
K80ME-C and S80ME-C
two-stroke engines
Page 7
Service Center Singapore
Serving the heart of Asia
Pages 8-9
Trans-Pacific engineering
Matsons boxships
re-engining project
Page 10
MAN B&W PrimeServ
One high-quality global
service network
Page 11
Diesel-electric precision
Chinese confidence in
L27/38 engines
Page 11
Influences on engine design
Matching ambient air
temperatures to engines
Pages 12-13
Modern training courses
New qualification for
MAN B&W Diesel
Page 14
Announcements
Latest news in short
Page 15
Chinese research ships
Off-shore seismic ships
propulsion solution
Back page
M/T Bow Firda (Odfjell, Norway) steaming towards further impressive results;
since entering service she has regularly returned fuel savings of 2.4%
Cross-sectional
drawing of the veeconfigured 51/60DF
four-stroke engine
DIESELFACTS
In addition to dismantling,
cleaning and measuring, the connecting rods were inspected for
cracks. After workshop approval,
they were also reassembled and
approved by the owner and classification society.
After cleaning and measuring in
the workshop, the cylinder liners
were honed control measured
followed by approval by the owner and classification society.
The fuel injection pumps were
dismantled, cleaned and measured in the workshop. It was
decided to replace all the plunger and barrels. In addition, one
complete fuel pump was replaced due to a seizure.
Inspection results for the fuel
injection nozzles in the workshop
showed that eight pieces should
be replaced and while a further
four pieces could be overhauled.
Turbochargers were dismantled
and the basic unit taken to the
workshop. They were cleaned,
measured, dynamically balanced
and the bearings renewed. The
housings were pressure tested
onboard the ship.
Main bearings and thrust bearings were opened and inspected
in the engines and approved by
the owner and the classification
society. None of the bearings
needed replacement.
All inlet and outlet valves, together with safety valves, starting
valves and indicator cocks were
cleaned and overhauled to the
approval of the owner and classification society.
While the various components
of the engine where being overhauled, MAN B&W Diesels service center electrical engineers
took the opportunity to overhaul
the shaft alternators, including
chemical cleaning of all the electrical wires in rotor and stator
followed by new lacquering.
Both white metal bearings on
the shaft generators were also
replaced. In addition, two bearings
were recast with white metal.
The engine frames and sumps
were cleaned in-situ on board the
ship while the parts were in the
workshop enabling a speedy
reassembly of the engines.
103.7 m
16.0 m
7.4 m
6.6 m
1904 tons
1364 tons
14.3 knots
Chernomorskyj, Ukraine
1988
Frozen whole fish, headed fish, fish
meal and fat. Stowage of frozen
products at a temperature of -28C
DIESELFACTS
continued from page 1
Executive statement:
Thomas S. Knudsen, Senior
Vice President, Research &
Development Two-stroke,
MAN B&W Diesel.
Bow Firdas engine room containing the electronically controlled 7S50ME-C main engine
DIESELFACTS
Emission limits:
Sulphur oxide:
Nitrogen oxide:
Particulate matter:
Urea
ESP
Caustic
Soda
(NaOH)
Transformer
DeSOx
Circulating pump
Jacket
cooler
L.O.
cooler
Stack
S.W. pump
Disposal of
DeSOx water
L.O. pump
Circulation pump
S.W. cooler
F.O. purifier
F.O. tank
S.W.
intake
Main Engine
F.O. transfer
pump
S.W. heater
S.W. discharge
Schedule
Companies
Generator
Acid
Generator
Engine type
DeNOx system
DeSOx system
03.4.25
Plan
Contractor
Builder
HSD Engine
Builder
Alstrom (Spain)
Builder
Haldor Topsoe
Builder
03.12.23
Procurement contract
Engineering
Hyundai Engineering
Efficiency
45.1%
Type
Air cooled
Type
SCR
Type
FGD
04.6.1~
Engine Supplier
HSD Engine
Fuel
Voltage
13.8 kW
Chemical
Urea
Chemical
NaOH
05.1.1
Installation
Environment
equipment supplier
Korea Kottel
Speed
109.1 rpm
Pole/Frequency
66/60
DeNOX rate
DeSOX rate
05.6.1~05.6.30
Commissioning
Construction
Commissioning
Cylinder
MCR/NCR
44.49kW/40.460kW
Outlet NOX
Outlet SOX
below 50 ppm
Schematic diagram of the power plant. An 8-metre wide poster version of the same image is located in the power plants guest area.
Korea Kottel
DIESELFACTS
Diesel Academy
Mr Lennart Cronhamn, Diesel Academy Manager, in the ME Simulator
training room at MAN B&W Diesels Headquarters in Copenhagen
Incresed flexibility
The increased flexibility permitted by the expansion enables
the Diesel Academy to offer
more tailor-made courses to
ship-owners, engineers and other professionals. The demand for
such courses, which are currently held at MAN B&W Diesels
Headquarters in Copenhagen,
recognises the need for new areas of competence by individuals within the institutions such
as classification societies and insurance companies, explains
Mr Cronhamn.
There are many advantages to
be gained by both new and experienced crew in obtaining
hands-on experience of electronically controlled engines.
For new crew, the mobile simulators can be seen as having the
two-fold benefit of giving personnel best practice routines
for both the electronically controlled ME engines and the previous generation of MC and
MC-C engines. Ship personnel
with previous experience of
DIESELFACTS
Aligning the new section with the crankshaft. A heat shield placed on
the heat treated crankshaft aids heat retention and protects workers.
Final machining of the new shaft section after being heat shrunk onto
the crankshaft
The repaired crankshaft, complete with gear wheel was dispatched to the
owners from Hamburg on January 26 by the same method as it arrived
Executive statement:
Dr. Tilmann Greiner, Senior
Vice President Service Center
Werk Hamburg, stated upon
successful completion of the
project, I am very happy to
help customers, especially in
such
unusual
cases.
Compared to alternative
solutions, the repair solution
undertaken by the staff at
Service Center Werk Hamburg
allows vessels to be returned
to operational service many
months earlier.
DIESELFACTS
W-seat
- Less deposits
- Improved combustion
process
- Emissions reduced
- Less visible smoke
OROS combustion
chamber
- Reduced surface
temperatures
- Elimination of
piston top coating
- Less piston top stress
Improved bedplate
design
- Better access for
inspections and
maintenance
- Twin stay bolts
- Reduced oilpan size
Power (kW/cyl.):
Speed (r/min):
SFOC (g/kWh):
Stroke (mm):
Bore (mm):
MEP (bar):
Pmax (bar):
Piston speed (m/s):
Lube oil consumption:
Guiding cyl. oil feed rate:
6-9S80ME-C
6-12K80ME-C
4510
78
167
3450
800
20
160
9
4530
104
171
2600
800
20
160
9
6-9 kg/cyl / 24 h
0.7 g/kWh
DIESEL
Felix Leggewie, Managing Director MAN B&W Diesel (Singapore) Pte. Ltd.
LFACTS
10
DIESELFACTS
C9 Class Vessels:
Length:
Speed:
Deadweight:
TEUs:
262 m
23.0 knots
30,167 t
2,824
on
Ramani Srinivasan (seated centre), Technical Director for Matson, Gene Mapa (second from right),
Dan Moylan (sixth from right) and members of the Matson Engineering Department
11
DIESELFACTS
Auxiliary/harbour GenSet:
9L16/24
Main GenSet:
6L27/38
Main GenSet:
6L27/38
Main GenSet:
6L27/38
Example power production layout, utilising three primary 6L27/38 GenSets and one auxiliary 9L16/24 GenSet
Principal particulars
Length oa.:
Length pp.:
Breadth:
Depth:
Draught:
Est. speed:
Endurance:
106 m
96 m
17.4 m
8.3 m
5.5 m
17 knots
15,000 Nm (unrestricted service)
GenSets:
Output:
Aux. GenSet:
Output:
12
DIESELFACTS
Turbocharger air
intake temperature
Up to 100% SMCR
running is not allowed
45
30
Standard
basis 25
10
5
0
-10
Up to 100% SMCR running
only allowed when low ambient
temperature exhaust gas
bypass is installed
-20
-25
1000 mbar
45oC
32oC
60%
46
Scavenge air
temperature limit
Scavenge air
temperature limit
Max. 55 C
Special
high temperature
matched engine
Standard
ISO temperature
matched engine
Maximum
scavenge air
temperature
at 100% SMCR
Maximum
scavenge air
temperature
at 100% SMCR
40
36
34
Standard 32 C
32
30
Standard
tropical
scavenge air
coolant
temperature
Max. 48 C
26
24
High tropical
scavenge air
coolant
temperature
Max. 40 C
High tropical
seawater
temperature
Max. 36 C
Standard tropical
seawater
temperature
High scavenge
air coolant
temperature
28
Standard
basis 25 C
ISO based
scavenge air
coolant
temperature
ISO based
design
layout
Max. 29 C
ISO
design
layout
22
Up to 100% SMCR
running is not allowed
(scavenge air)
Normal min.
winter
temperature
Lowest
winter
temperature
Fig.1: Principles for standard and special high ambient air temperature matched engine
42
Standard 36 C
Special
basis
-40
44
38
Min.
-10 C
-15
Temperature oC
48
Min.
-5
-35
Standard 48 C
ISO
design
layout
ISO based
design
layout
15
50
ISO
25 C
Special
design
temperature
20
Up to 100% SMCR
running is allowed
-30
52
Normal
tropical
temperature
35
54
Max.
45 C
Special
tropical
temperature
40
Standard 55 C
Max.
50
56
Standard
ISO temperature
matched engine
55
Special
High temperature
matched engine
Up to 100% SMCR
running is allowed
(scavenge air)
Up to 100% SMCR
running is allowed
(scavenge air coolant/
central cooling water)
Up to 100% SMCR
running is allowed
(seawater)
Fig.2: Principles for layout of scavenge air cooler for standard and special high scavenge air coolant
temperature (illustrated for a central cooling water system using a standard air cooler design)
standard and special high ambient air temperature matched engine are shown in Fig. 1.
Low air temperature matched
engine
At the other end of the air
temperature range, the same
increase of 5oC in the design
air intake temperature will
result in a too high scavenge
air pressure when operating
at -10 oC. Operation below
-10+5=-5oC will then only be
possible when installing a
variable exhaust gas bypass
valve system for low air
temperatures.
Ensuring good combustion
chamber conditions
For high tropical seawater/
scavenge air coolant temperature-matched engines, an increase of the scavenge air coolant
temperature will involve a similar increase of the scavenging air
temperature. This has a negative
impact on the combustion chamber temperatures. Therefore an
alarm set point of 55oC is applied
for protection of the engine on
all marine applications.
The standard marine scavenge
air cooler is specified with a maximum 12oC temperature difference between cooling water
inlet to scavenge air outlet at
100% SMCR. This gives a maximum scavenge air temperature
13
DIESELFACTS
Turbine
Turbocharger
C1+2
D1
Scavenge
air receiver
Scavenge
air cooler
Diesel engine
D
D1
D2
Fig. 3: Standard load dependent low ambient temperature exhaust gas for bypass system
kg/h
6S60MC-C/ME-C
SMCR = 13,560 kW at 105 r/min
Total steam
production,
with exhaust
gas bypass
2,000
Surplus steam
Total steam
production,
without bypass
1,500
Steam
consumption
Extra steam
needed
1,000
500
0
40
50
60
70
80
Compressor
D2
Steam production
2,500
90
100%
SMCR
Conclusion
When fitted with a bypass,
these engines will normally be
able to operate worldwide in
unrestricted service without
any precautions being taken.
Even if the ship has to operate
in extremely hot or cold areas,
the MAN B&W Diesel engines
can, as this article illustrates,
also operate under such conditions without any problems as
long as some simple precautions have been taken.
14
DIESELFACTS
Dr. Timmermann
MAN B&W Diesel 12K98MC engine built by HHI with 101,640 BHP
Engine data:
Type: 12K98MC
Power: 101,640 bhp
(74,760 kW)
Speed: 97 r/min
MEP:
19.2 bar
Height: Approx. 16 m
Width: Approx. 11 m
Length: Approx. 25 m
Weight: Approx. 2,100 t
The 9000+ TEU container vessel owned by Costamare and chartered to COSCON
ANNOUNCEMENTS
15
DIESELFACTS
SWL5T 2-12M
The vessels will each be specified and equipped for their very
specific operational tasks, i.e.
seismic sourcing and seismic
recording. The vessels are designated as an OBC Source Vessel
and an OBC Recorder Vessel,
respectively. The OBC abbreviation refers to Ocean Bottom
Cable and the actual seismic
exploration equipment applied.
SCM
Propulsion Package
Principal Particulars:
Length oa:
Length pp:
Breadth:
Depth:
Draught:
Crew:
65.0
58.4
13.8
5.1
3.5
45
m
m
m
m
m
Main Engines:
Two MAN B&W Diesel
6L23/30A-D engines, resiliently seated with baseframe
and sandwich mountings.
Each engine develops 960 kW
at 900 r/min.
Reduction Gearboxes:
Two MAN B&W Diesel Alpha
AMG8 gearboxes (type
31VO8), with a speed reduction ratio of 900:292.
Propellers:
Two MAN B&W Diesel Alpha
VB560 four-bladed controllable pitch propellers. The
1,900 mm diameter CPP systems are complete with tail
shafts, intermediate shafts,
bearings and stern tube
equipment. Epoxy coated
tailshafts with bronze liners
are applied for water lubricated stern tubes.
Control System:
In addition to the twin main
bridge control station, the
www.manbw.com
MAN B&W Diesel A/S
Publisher
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Peter D. Petersen
MAN B&W Diesel A/S
Copenhagen
Denmark
Tel.: (+45) 33 85 11 00
Fax.: (+45) 33 85 10 30
Copyright owned by
MAN B&W Diesel
except where mentioned
Tel.: (+45) 33 85 11 00
E-mail: dieselfacts@dk.manbw.com